Structured cushioning articles with thermal insulation properties

Abstract

The present disclosure relates generally to the field of cushioning articles, more specifically to the field of cushioning articles having thermal insulation properties. The present disclosure also relates to cushioning articles having a structured surface and to their use for industrial applications, in particular for thermal management applications in the transportation industry.

Description

[0001] STRUCTURED CUSHIONING ARTICUES WITH THERMAE INSULATION PROPERTIES

[0002] The present disclosure relates generally to the field of cushioning articles, more specifically to the field of cushioning articles having thermal insulation properties. The present disclosure also relates to cushioning articles having a structured surface and to their use for industrial applications, in particular for thermal management applications in the transportation industry.

[0003] BACKGROUND

[0004] Automotive electrification is currently one of the biggest trends in the automotive industry. Within this trend, the propulsion with electric energy supplied by electric batteries and the development of suitable electric vehicle batteries as energy storage devices are the main focus in the automotive industry. Electric-vehicle batteries are used to power the propulsion system of battery electric vehicles (BEVs) and hybrid electric vehicles (HEVs). These batteries, which are typically lithium ion batteries, are designed with a high ampere hour capacity. The trend in the development of electric vehicle batteries goes to higher energy density in the battery (kWh / kg) to allow the covering of longer distances and to reducing charging times of the battery.

[0005] Due to the high energy density of electric vehicle batteries and the high energy flow during charging or discharging of the battery, there is a risk of creation of hot spots and thermal runaway events where the heat generated by the decomposition of battery cells propagates very rapidly to neighboring cells. This chain reaction might lead to the explosion or the fire catching of the whole electric vehicle.

[0006] Moreover, during the normal life cycle of these energy storage devices, in particular during fast charging and discharging cycles of electric vehicle batteries, the battery cells used for such battery modules tend to expand and retract continuously. These expansion / contraction cycles can put the battery cells under considerable pressure conditions, which in turn may lead to mechanical damage of the battery cells.

[0007] In that context, the use of thermal management solutions has rapidly emerged as one way the mitigate the temperature rise in battery assemblies. One partial solution is disclosed in US-A1- 2007 / 0259258 (Buck) which describes the use of heat absorbing material to absorb the heat generated by the battery cells of a battery pack assembly and transfer heat out from the case of the assembly thereby maintaining a lower temperature inside each battery pack and the overall battery assembly. Another partial solution is described in US-A1-2019393574 (Goeb et al.) which discloses the use of thermally conductive gap filler compositions comprising thermally conductive filler material for cooling battery assemblies. Still another partial solution is described in US-A1-2016 / 0308186 (Han), which discloses a battery module including battery cells arranged adjacent to each other along a first direction, a spacer between neighboring battery cells, and a multi-layer insulation sheet between the neighboring battery cells together with the spacer, wherein the multi-layer insulation sheet includes a plurality of insulation layers extending in parallel with the surfaces of the battery cells. SUMMARY

[0008] According to one aspect, the present disclosure relates to a cushioning article comprising a nonsyntactic polymeric foam layer having at least one structured surface.

[0009] According to another aspect, the present disclosure is directed to a process for manufacturing a cushioning article as described above.

[0010] According to yet another aspect, the present disclosure relates to the use of a cushioning article as described above, for industrial applications, in particular for thermal management applications in the transportation industry.

[0011] The following definitions apply to concepts used elsewhere in this application, including the claims.

[0012] The term “predominantly inorganic layer” in the context of this application refers to a layer composed of inorganic materials, which may optionally further include an organic binder. The inorganic materials constitute the majority of the layer's composition and provide the primary structural and functional characteristics of the layer. The organic binder, if present, may serve to hold together the fiber matrix that may be part of the inorganic layer, such as, for example, bonding together inorganic fibers and inorganic filler particles (if present) within the inorganic layer.

[0013] The term “adjacent” refers to the relative position of two elements, such as, for example, two layers, that are close to each other and may or may not be necessarily in contact with each other or that may have one or more layers separating the two elements as understood by the context in which “adjacent” appears.

[0014] The term “immediately adjacent” refers to the relative position of two elements, such as, for example, two layers, that are next to each other and in contact with each other and have no intermediate layers separating the two elements.

[0015] The term “repeating pattern” refers to an arrangement of elements, such as structures, on a surface, where the structures are consistently spaced and oriented in a predictable and regular manner. This pattern is characterized by periodic repetition, meaning that the distances between individual structures are uniform, and the alignment follows a consistent interval. The structures within a repeating pattern maintain consistent spatial dimensions, creating a uniform and orderly arrangement when viewed from a top plane.

[0016] The structures part of the articles of the present disclosure are “engineered structures,” which refers to a structure having a shape with a deliberate design, which is in contrast to a random structure.

[0017] In the present application, a first set of structures may be different from a second set of structures with respect to cross sectional shape when: (a) the geometric shape of the cross-section of the structures is different from each other (which can include shapes such as triangular, square, rectangular, truncated triangular (trapezoidal), shapes defined by a cubic Bezier function, etc.) and (b) differences in dimension when the cross-sectional shape is the same for both sets, but the size of the structures varies. For example, both sets of structures may have a trapezoidal cross-sectional shape, but one set of structures may be higher or wider than the other. Throughout this disclosure, the terms truncated triangular and trapezoid are being used synonymously.

[0018] In the present application, a first set of structures may be different from a second set of structures with respect to spacing between the structures when the distance or pitch between individual structures within a set. This refers to the interval or spacing between adjacent structures. For example, one set of structures may have a smaller pitch (closer spacing) compared to another set of structures with a larger pitch (wider spacing).

[0019] In the present application, a first set of structures may be different from a second set of structures with respect to composition when material makeup of one set of structures is different from the material makeup of the other set of structures, which can include variations in the type of elastomer used (silicone, polyurethane, etc) but also differences in the presence or type of fillers or other additives.

[0020] These differences with respect to cross sectional shape, spacing between the structures, and composition can be independently chosen for each set of structures.

[0021] The term “substantially flat” for a given layer refers to a surface of that layer having a surface roughness of less than 3% the total thickness of that layer.

[0022] The term “foam” or “foamed” refers to a polymer that has a cellular structure with numerous generally uniformly distributed air cavities (e.g., cells or bubbles) throughout the material. Closed cell foams have isolated bubbles, while open cell foams have a network of interconnected cells.

[0023] When the void fraction produced by structuring of the surface of the polymeric foam layer is considered (e.g., void space in between structures in Figures 7A, and 7B,) the density of the polymeric foam layer having the structures is defined as “bulk density.” In this case, the density of the polymeric foam material remains the same, but the density of the structured layer decreases due to incorporation of void space from the structured surface.

[0024] BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIGs. 1 A-C illustrate an exemplary battery module assemblies having various thermal insulation layers between battery cells.

[0026] FIGs. 2A-2B illustrate show an exemplary structure of a non-syntactic polymeric foam layer.

[0027] FIGs. 3A-3B are cross-sectional side views of the structured polymeric foam layers of the present disclosure.

[0028] FIGs. 4A-4C show cross-sectional images of some exemplary shapes the structures of the structured polymeric foams of the present disclosure.

[0029] FIGs 5A-5B show top down schematics of exemplary battery assemblies having structured Cushioning layers between battery cells.

[0030] FIGs 6A-6B show cross sectional side views of exemplary cushioning layer assemblies where the structured polymeric foam layer can be combined with another layer which provides additional beneficial properties.

[0031] FIGs. 7A-7B show top down schematics of exemplary battery assemblies having structured Cushioning layers in combination with additional layers used for insulation between battery cells.

[0032] FIG. 8A-8B are cross-sectional side views of the structured polymeric foam layers of the present disclosure.

[0033] FIG. 9 shows a top down schematic of an exemplary battery assembly having structured Cushioning layers in combination with additional layers used for insulation between battery cells.

[0034] FIG. 10 are cross-sectional side views of the structured polymeric foam layers of the present disclosure.

[0035] FIG. 11 are cross-sectional side views of the structured polymeric foam layers of the present disclosure.

[0036] FIGs. 12A and 12B Micrographs of two structured polymeric foams, example 1 and example 2.

[0037] FIGs. 13A and 13B Graphs of thermal conductivity improvement and CFD curves for Experimental samples 1 and 2 versus control Comparative Example 1.

[0038] FIGs. 14A- 14E Structured tool designs for experimental examples 3-7.

[0039] FIGs. 15A- 15E Structured tool designs for experimental examples 8-12.

[0040] FIG. 16A cross sectional optical micrographs of structure cushioning layers of examples 13-17.

[0041] FIG. 16B cross sectional optical micrographs of structure cushioning layers of examples 18-21.

[0042] FIG. 17A compression force deflection curves of structure cushioning layers of examples 13-17 and comparative example CE 2.

[0043] FIG. 17B compression force deflection curves of structure cushioning layers of examples 18-21 and comparative example CE 2.

[0044] FIG. 18A cross sectional optical micrograph of structure cushioning layers of example2 22.

[0045] FIG. 18B compression force deflection curves of structure cushioning layers of example 22 and comparative example CE 2.

[0046] DETAILED DESCRIPTION

[0047] Figures 1A - 1C illustrate three example battery module assemblies comprising three different insulating cushioning layer options between battery cells.

[0048] FIG. 1A illustrates an exemplary generic assembled battery module 100 which comprises a plurality of battery cells 160 separated from each other by a gap, and a plurality of cushioning articles 150 positioned in the gap between the battery cells 160. The battery module is further provided with a base plate 180 upon which is positioned a thermally conductive gap filler 170. Figure 1A shows a battery assembly wherein the cushioning article comprises a polymeric foam layer 150 having a thickness and two planar major surfaces which contact adjacent battery cells 160.

[0049] FIG. IB illustrates an exemplary generic assembled battery module 100 which comprises a plurality of battery cells 160 separated from each other by a gap, and a plurality of composite or multilayer cushioning articles 150 positioned in the gap between the battery cells 160. The battery module is further provided with a base plate 180 upon which is positioned a thermally conductive gap fdler 170. The cushioning article 150 comprises a predominantly inorganic layer 155, which is designed to provide additional thermal insulation and thermal stability benefits, with polymeric foam cushioning layers, 154, positioned on either side of the predominantly inorganic layer 155. The polymeric foam layers having a thickness and two nominally planar major surfaces one of which contacts the predominantly inorganic layer 155 and the other that contact adjacent battery cells 160.

[0050] FIG. 1C illustrates another exemplary generic assembled battery module 100 which comprises a plurality of battery cells 160 separated from each other by a gap, and a plurality of composite or multilayer cushioning articles 150 positioned in the gap between the battery cells 160. The battery module is further provided with a base plate 180 upon which is positioned a thermally conductive gap filler 170. The cushioning article 150 comprises a predominantly inorganic layer 155, which is designed to provide additional thermal insulation and thermal stability benefits, with a polymeric foam cushioning layer, 154, such that an asymmetric multilayer cushioning article 150 is positioned between adjacent battery cells. The polymeric cushioning layer having a thickness and two nominally planar major surfaces one of which contacts the predominantly inorganic layer 155 and the other that contacts a battery cell 160. The predominantly inorganic layer 155 contacts the polymeric foam layer 154 with one of it’s major surfaces and an adjacent battery cell 160.

[0051] Figures 2A and 2B show additional detail of the polymeric cushioning layer of Figures 1A- 1C. The polymeric cushioning layer, 250, as shown in Figure 2A can be made of any type of useful material as long as it demonstrates adequate thermal properties for the use case of interest. In many cases, the cushioning layer 250 is a polymeric foam that can be made by any known means. In some cases, this polymeric foam may comprise filled crosslinked polysiloxanes, polyurethanes, polyamides and other thermally stable foam compositions. Further description of foam layers will be described elsewhere. As shown in Figure 2B, the foam has a measurable thickness, t, that can be in the range of from about 0.5mm to about 8mm or from about 0.5mm to about 6mm, or from about 0.5mm to about 5mm, or from about 0.8mm to about 4mm, or from about 0.8mm to about 3.5mm. The polymeric foam material shown in Fig. 2B comprises cells or gas filled pockets or pores, 251. Particularly useful cell structures include closed cell pore structures where fluid cannot penetrate the cushioning layer though it’s thickness, t. Figure 3A shows an illustrative example of structured cushioning layer 350 of the present disclosure. In contrast to the cushioning layers shown in Figures 1A-1C and Fig. 2A-2B, the Cushioning layer 350, comprises two major surfaces, one being non-planar. A first major surface of the cushioning layer, 352 comprises a structured surface which has structures, 352a, having at least some facets or surfaces, 352b, that are non-parallel to the major surface 352, where the major surface 352 is defined as connecting to the tops of the outer most portions of the structures. The first major surface has geometric shapes (linear triangular prisms shown in Fig. 3A), wherein the height of the prisms, hi, relative to the total height / thickness, 112, of the cushioning article has a ratio of at least 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0.1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.25 to about 0.5. In some embodiments, The first major surface having a geometric shapes (linear triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio from about 0.05 to about 0.95, or from about 0.1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95. The second major surface, 353 is nominally flat and non-structured, with a surface roughness of less than 3% of the total thickness.

[0052] Figure 3B shows another illustrative of structured cushioning layer 350 of the present disclosure. In contrast to the cushioning layers shown in Figures 1A-1C and Fig. 2A-2B, the Cushioning layer 350, comprises two major surfaces, where both are non-planar. A first major surface of the cushioning layer, 352 comprises a structured surface which has structures, 352a, having at least some facets or surfaces, 352b, that are non-parallel to the major surface 352, defined as connecting to the tops of the outer most portions of the structures. The first major surface has geometric shapes (linear triangular prisms shown in Fig. 3B), where in the height of the prism, hi, relative to the total height / thickness, 112, of the cushioning article has a ratio of at least 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0. 1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.2 to about 0.4. In some embodiments, The first major surface having a geometric shapes (linear triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio from about 0.05 to about 0.95, or from about 0.1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95. A second major surface of the cushioning layer, 353 comprises a structured surface which has structures, 353a, having at least some facets or surfaces that are non-parallel to the major surface 353, where the second major surface 353 is defined as connecting to the tops of the outer most portions of the structures. The second major surface has geometric shapes (linear triangular prisms shown in Fig. 3B), where in the height of the prism, hl, relative to the total height / thickness, I12, of the cushioning article has a ratio of at least 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0.1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.2 to about 0.4. In some embodiments, the first major surface having a geometric shapes (linear triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio from about 0.05 to about 0.95, or from about 0. 1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95. While shown as having the same structured surface in Fig. 3B, it will be appreciated that the two structured surfaces 352 and 353 may have different geometric shapes and sizes depending on what properties are required of the structured cushioning layer in application.

[0053] Figure 4A - 4C show a few examples of different geometric shapes, 452a and 453a which can be used for the structured surfaces of the present disclosure. These few examples are not meant to be limiting in any way and are used only as reference of a few of the types of structures that can be useful.

[0054] Fig. 4A, shows a triangular prism shape 452a and 453a, (similar to that shown in Fig. 3A and 3B) which when extended into the page create linear triangular prisms. Preferred triangular prisms may have 0i angles of from about 50° to about 120°. In some embodiments the triangular prisms are symmetric where angles 02 and 03 are equal and their angles are defined as [(180° - 0i) / 2], In some embodiments, 02 and 03 can be different, thus creating asymmetric linear prism structures. In most cases, neither 02 or 03 should exceed 90°.

[0055] Figure 4B shows truncated triangular prism (or trapezoid) structures 452a and 453a, where each prism has a flat top with angled sides which when extended into the page created linear truncated triangular prisms. In some embodiments, the shapes are near symmetric in shape, where angle, 0i can have angles from about 50° to about 90° and 02 has a complimentary angle from about 130° to about 90° respectively. In some embodiments, the structures may be asymmetric in shape.

[0056] Figure 4C shows another type of geometric shape that may be used to make linear “prisms” 452a and 453a. This “prism” or geometric shape can be defined as a structure having a smoothly varying outer surface such as can be defined by a cubic Bezier Function, where the “prism” or geometric shape can range from approximating a half ball lens (half hemisphere) to that approximating a bullet like shape. This shape can be extended into the page to make linear prisms having a smoothly curved outer surface.

[0057] Figure 5A shows an illustrative top down view of an exemplary battery assembly module with the structured cushioning article of Figure 3A. The battery module 500 which comprises a plurality of battery cells 560 separated from each other by a gap, and a plurality of cushioning articles 550 positioned in the gap between the battery cells 560. The base plate upon which the battery is positioned with thermally conductive gap filler is not shown. Figure 5A shows a battery assembly module wherein the cushioning article comprises a polymeric foam layer 550 having a structure on one of the two major surfaces of the cushioning layer as described in Fig. 3A, where the tips of the prisms of the structured surface contact one battery cell, 560 and the nominally planar surface of the cushioning layer contact an adjacent cell. The structured side of the cushioning article 550 in contact with the battery cell 560, defines airgaps, 590, between the battery cell 560 and cushioning layer 550. These air gaps serve to reduce the effective thermal conductivity of the cushioning layer. Additionally, these defined air gaps created a directional channel for gasses to be vent preferentially away from the battery in the event of thermal runaway event. In many embodiments the surface prisms of the cushioning layer 550 are a compressible polymeric foam structure and modify the force or stress exerted on the battery cell relative to the same cushioning material having two flat major surfaces, both in full contact with the adjacent cell surfaces.

[0058] Figure 5B shows an illustrative top down view of an exemplary battery assembly module with the structured cushioning article of Figure 3B. The battery module 500 which comprises a plurality of battery cells 560 separated from each other by a gap, and a plurality of cushioning articles 550 positioned in the gap between the battery cells 560. The base plate upon which the battery is positioned with thermally conductive gap filler is not shown. Figure 5B shows a battery assembly module wherein the cushioning article comprises a polymeric foam layer 550 having surface structure on both of the two major surfaces of the cushioning layer as described in Fig. 3B, where the tips of the prisms of the two structured surfaces contact adjacent battery cells 560. The structured sides of the cushioning article 550 in contact with the battery cells 560, defines airgaps, 590, between the battery cells 560 and cushioning layers 550. These air gaps serve to reduce the effective thermal conductivity of the cushioning layer. Additionally, these defined air gaps created a directional channel for gasses to be vent preferentially away from the battery in the event of thermal runaway event. In many embodiments the surface prisms of the cushioning layer 550 are a compressible polymeric foam structure and modify the force or stress exerted on the battery cell relative to the same cushioning material having two flat major surfaces, both in full contact with the adjacent cell surfaces.

[0059] Figure 6A shows an illustrative side view of a single side structured cushioning layer 650 comprised of structured polymeric foam layer 654 and a predominantly inorganic layer 655. The structured polymeric foam layer 654 comprises two major surfaces. A first major surface of the cushioning layer, 652 comprises a structured surface which has structures, 652a, having at least some facets or surfaces, 652b, that are non-parallel to the major surface 652, defined as connecting to the tops of the outer most portions of the structures. First major surface having a geometric shapes (linear triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, 112, of the cushioning article has a ratio of at least 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0.1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.2 to about 0.4. In some embodiments, The first major surface having a geometric shapes (linear triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio from about 0.05 to about 0.95, or from about 0. 1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95. The second major surface, 653 is nominally flat and non-structured, with a surface roughness of less than 3% of the total thickness and is in contact with a predominantly inorganic layer 655, which may impart additional thermal and mechanical benefits to the insulting cushioning layer 650.

[0060] Figure 6B shows another illustrative of structured cushioning layer 650 of the present disclosure. In contrast to the cushioning layers shown in Figures 1A-1C and Fig. 2A-2B, the Cushioning layer 650, comprises two major surfaces. A first major surface of the cushioning layer, 652 comprises a structured surface which has structures, 652a, having at least some facets or surfaces, 652b, that are non-parallel to the major surface 652, defined as connecting to the tops of the outer most portions of the structures. First major surface having a geometric shapes (linear trigonal prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio of at least 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0. 1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.2 to about 0.4. In some embodiments, The first major surface having a geometric shapes (linear triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio from about 0.05 to about 0.95, or from about 0. 1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95. A second major surface of the cushioning layer, 653 comprises a structured surface which has structures, 653a, having at least some facets or a surfaces, 653b, that are non-parallel to the major surface 653, defined as connecting to the tops of the outer most portions of the structures. First major surface having a geometric shapes (linear triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio of at least 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0. 1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.2 to about 0.4. In some embodiments, The first major surface having a geometric shapes (linear triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio from about 0.05 to about 0.95, or from about 0. 1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95. While shown as having the same structured surface in Fig. 6B, it will be appreciated that the two structured surfaces 652 and 653 may have different geometric shapes and sizes depending on what properties are required of the structured cushioning layer in use.

[0061] Figure 7A shows an illustrative top down view of an exemplary battery assembly module with the structured cushioning article of Figure 6A. The battery module 700 which comprises a plurality of battery cells 760 separated from each other by a gap, and a plurality of cushioning articles 750 positioned in the gap between the battery cells 760. The base plate upon which the battery is positioned with thermally conductive gap fdler is not shown. Figure 7A shows a battery assembly module wherein the cushioning article comprises a polymeric foam layer 750 having a structure on one of the two major surfaces of the cushioning layer 754 as described in Fig. 6A, where the tips of the prisms of the structured surface contact one battery cell, 760 and the nominally planar surface of the cushioning layer contact a predominantly inorganic layer 755, which contacts an adjacent cell. The structured side of the cushioning article 750 in contact with the battery cell 760, defines airgaps, 790, between the battery cell 760 and cushioning layer 750. These air gaps serve to reduce the effective thermal conductivity of the cushioning layer. Additionally, these defined air gaps created a directional channel for gasses to be vented preferentially away from the battery in the event of thermal runaway event. In many embodiments the surface prisms of the cushioning layer 750 are a compressible polymeric foam structure and modify the force or stress exerted on the battery cell relative to the same cushioning material having two flat major surfaces, both in full contact with the adjacent cell surfaces.

[0062] Figure 7B shows an illustrative top down view of an exemplary battery assembly module 700 with the structured cushioning article of Figure 6B. The battery module 700 which comprises a plurality of battery cells 760 separated from each other by a gap, and a plurality of cushioning articles 750 positioned in the gap between the battery cells 760. The base plate upon which the battery is positioned with thermally conductive gap filler is not shown. Figure 7B shows a battery assembly module wherein the cushioning article comprises a polymeric foam layers 754 having surface structure on one of the two major surfaces of the polymeric foam layer as described in Fig. 6B, where the tips of the prisms of the two structured surfaces contact adjacent battery cells 760. The nominally planar sides of the two polymeric foam layers, 754, are in contact with the two sides of the predominantly inorganic layer 755, such that polymeric foam layers, 754, of the cushioning layer, 750, separate the inorganic layer, 755, from the battery cells. The structured sides of the cushioning article 750 in contact with the battery cells 760, defines airgaps, 790, between the battery cells 760 and cushioning layers 750. These air gaps serve to reduce the effective thermal conductivity of the cushioning layer. Additionally, these defined air gaps created a directional channel for gasses to be vent preferentially away from the battery in the event of thermal runaway event. In many embodiments the surface prisms of the cushioning layer 750 are a compressible polymeric foam structure and modify the force or stress exerted on the battery cell relative to the same cushioning material having two flat major surfaces, both in full contact with the adjacent cell surfaces.

[0063] A further embodiment of the surface structured cushioning layer, 850, can be seen in Figure 8A. A structured cushioning layer, 850, having truncated triangular prisms is shown. A first major surface of the cushioning layer, 852 comprises a structured surface which has structures, 852a, having at least some facets or surfaces, 852b, that are non-parallel to the major surface 852, defined as connecting to the tops of the outer most portions of the structures. The geometric structures, 852a, of the first major surface are spaced apart and have gaps between them with predominantly flat regions parallel to the first major surface 852 defined by the tips of the prisms 852a. The pitch of the prism structures (repeat distance) P2 relative to the width of the individual prisms Pi can have a ratio from 1 to about 10, or from about 2 to about 8, or from about 2 to about 6, or from about 2 to about 4. The first major surface has geometric shapes (linear truncated triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio of at least 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0.1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.2 to about 0.4. In some embodiments, the first major surface having a geometric shapes (linear triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio from about 0.05 to about 0.95, or from about 0.1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95. The second major surface, 853 is nominally flat and non-structured, with a surface roughness of less than 3% of the total thickness.

[0064] Figure 8B shows an illustrative example of a useful embodiment of the present disclosure which can provide for beneficial structural elements that can be used to tune the mechanical response of the cushioning layer under compression. A structured cushioning layer, 850, having truncated triangular prisms having two different sizes is shown. A first major surface of the cushioning layer, 852 comprises a structured surface which has structures, 852a, having at least some facets or surfaces, 852b, that are nonparallel to the major surface 852, defined as connecting to the tops of the outer most portions of the structures. The geometric structures, 852a, of the first major surface are spaced apart and have gaps between them with predominantly flat regions parallel to the first major surface 852 defined by the tips of the prisms 852a. The pitch of the prism structures (repeat distance) P2 relative to the width of the individual prisms Pi can have a ratio from 1 to about 10, or from about 2 to about 8, or from about 2 to about 6, or from about 2 to about 4. The first major surface has geometric shapes (linear truncated triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio of at least 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0.1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.2 to about 0.4. In some embodiments, The first major surface having a geometric shapes (linear triangular prisms), where in the height of the prism, hi, relative to the total height / thickness, I12, of the cushioning article has a ratio from about 0.05 to about 0.95, or from about 0. 1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95. A second set of geometric structures, 857a, define a second surface, 857 and have at least some facets or surfaces, 857b, that are non-parallel to the major surface 857. The geometric structures, 857a, of the first major surface are spaced apart and have gaps between them with predominantly flat regions parallel to the first major surface 857 defined by the tips of the prisms 857a. The pitch of the prism structures (repeat distance) P4 relative to the width of the individual prisms P3 can have a ratio from 1 to about 10, or from about 2 to about 8, or from about 2 to about 6, or from about 2 to about 4. In some embodiments, the pitch of the larger prisms, P2, is close to the pitch of the smaller prisms, P4, such that the ratio of the P2 to P4 is about 1 with a variability of about + / - 0.2. In all cases though the height of the second prism, 857a, is smaller than the height of the prisms, 852a and the ratio of heights hi to ha can be in the range of from about 1.1 to about 4 or from about 1.2 to about 3.5, or from about 1.5 to about 3. While Figure 8 shows an illustrative example with two different sizes of structures it is not meant to be limiting in scope and it is anticipated that 3 or more prism sizes may be used in order to provide for different handles for tuning mechanical response as a function of compression (strain).

[0065] Figure 9 shows an illustrative top down view of an exemplary battery assembly module 900 with the structured cushioning article comprised of two layers of the cushioning layer shown in Figure 8B on either side of a predominantly inorganic layer and similar to the construction shown in Figure 7B. The battery module 900 which comprises a plurality of battery cells 960 separated from each other by a gap, and a plurality of cushioning articles 950 positioned in the gap between the battery cells 960. The base plate upon which the battery is positioned with thermally conductive gap filler is not shown. Figure 9 shows a battery assembly module wherein the cushioning article comprises a polymeric foam layers 954 having surface structure on one of the two major surfaces of the polymeric foam layer as described in Fig. 8B, where the tips of the prisms of the two structured surfaces contact adjacent battery cells 960. The nominally planar surfaces, 953, of the two polymeric foam layers, 954, are in contact with the two major surfaces of the predominantly inorganic layer 955, such that polymeric foam layers, 954, of the cushioning layer, 950, separate the inorganic layer, 955, from the battery cells, 960. The structured sides of the cushioning article 950 in contact with the battery cells 960, define airgaps, 990, between the battery cells 960 and cushioning layers 950. These air gaps serve to reduce the effective thermal conductivity of the cushioning layer. Additionally, these defined air gaps created a directional channel for gasses to be vent preferentially away from the battery in the event of thermal runaway event. In many embodiments the surface prisms of the cushioning layer 950 are a compressible polymeric foam structure and modify the force or stress exerted on the battery cell relative to the same cushioning material having two flat major surfaces, both in full contact with the adjacent cell surfaces. Because there are two different heights of surface prisms, 952a and 957a respectively (see reference in Figure 8B description) there are two different distinct compression regimes when the cushioning layer undergoes compression. At low strains only the taller set of structures 952a are in contact with the battery cells and exert a force on the battery cell up to a certain strain value. As the strain increases and the cushioning layer is compressed the second set of prisms, 957a, then contact the battery cell and the stress or force on the battery cell is increased. The ability to tune the number, size and shape of the structures used in the cushioning layer allows for the ability to the force deflection values as a function of strain, which in sensitive battery architectures provide a valuable handle to controlling battery performance and life.

[0066] Figure 10 shows an illustrative example of structured cushioning layer 1050 similar to that of Figure 3A of the present disclosure. Cushioning layer 1050, comprises two major surfaces, one being non-planar and comprising an engineered structure. A first major surface of the cushioning layer, 1052 comprises a structured surface which has structures, 1052a, having at least some facets or surfaces, 1052b, that are non-parallel to the major surface 1052, where the major surface 1052 is defined as connecting to the tops of the outer most portions of the structures. The first major surface has geometric shapes (linear triangular prisms shown in Fig. 10), wherein the height of the prisms, hi, relative to the total height / thickness, 112 + h . of the cushioning article has a ratio of at least 0.03 to about 0.75, or from 0.05 to about 0.75, or from about 0. 1 to about 0.75 or from about 0.2 to about 0.75, or from about 0.25 to about 0.75. The second major surface, 1053 is nominally flat and non-structured, with a surface roughness of less than 3% of the total thickness. What is unique about figure 10 relative to figure 3A is that the cushioning layer of figure 10 can have two or more different polymeric foam compositions which make up the cushioning layer 1050. By different compositions, it is meant that the chemical composition of layer 1056 is different than layer 1057. This compositional difference may include differences in chemical composition of the polymeric foam layer and / or may include differences in foam structure, for example a significant difference in avg cell size of the foam layers and different densities. Figure 10 is meant to be illustrative in nature focused on the use of two or more layers with different compositions. It will be understood that the use of 2 or more layers in a structured foam can be extended to example previously described in foam descriptions of 3A, 3B, 4A, 4B, 4C, 8A and 8B, where in the structured cushioning layers can be structured on one or both of the major surfaces and the shapes of the structures can be variable and that the spacings aspect ratios of the structures previously described can be used with foams containing two or more compositionally different layers. In some embodiments, one of the two layers may comprise an elastomeric solid composition. Lastly, it will be appreciated that while the interface 1059 between the two compositionally different layers is shown as a discrete transition in the figure, the interface between layers may have structure and / or interpenetration of the two layers that may create an intermediate compositionally distinct layer. In some embodiments this third layer may have a gradient composition between compositional layers 1056 and 1057.

[0067] Figure 11 shows a further embodiment where the structured cushioning layer 1150, comprises a structured layer 1156 comprising a solid polymeric material (not a foam, but as an example a crosslinked elastomer), while the bulk of the cushioning layer 1157 comprises a polymeric foam layer. Cushioning layer 1150, comprises two major surfaces, one being non-planar and comprising an engineered structure. A first major surface of the cushioning layer, 1152 comprises a structured surface which has structures, 1152a, having at least some facets or surfaces, 1152b, that are non-parallel to the major surface 1152, where the major surface 1152 is defined as connecting to the tops of the outer most portions of the structures. The first major surface has geometric shapes (linear triangular prisms shown in Fig. 11), wherein the height of the prisms, hi, relative to the total height / thickness, I12 + h . of the cushioning article has a ratio of at least 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0. 1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.25 to about 0.5. In other embodiments, that ratio can be from at least 0.03 to about 0.75, or from 0.05 to about 0.75, or from about 0.1 to about 0.75 or from about 0.2 to about 0.75, or from about 0.25 to about 0.75. The second major surface, 1153 is nominally flat and nonstructured, with a surface roughness of less than 3% of the total thickness. As seen in figure 11, hi can be less than I12 (the thickness of the solid layer). In some embodiments, it may be desired to minimize the thickness of the land of the solid layer (I12 - hi). In some embodiments, I12 equals hi and there is no continuous solid land layer. It will be understood that the use of 2 or more layers in a structured foam can be extended to example previously described in foam descriptions of 3A, 3B, 4A, 4B, 4C, 8A and 8B, where in the structured cushioning layers can be structured on one or both of the major surfaces and the shapes of the structures can be variable and that the spacings aspect ratios of the structures previously described. It will be understood that the articles described in Figure 11 can be used as cushioning layers in battery assemblies as described in Figures 5A, 5B, 6A, 6B, 7A, and 7B. Lastly, it will be appreciated that while the interface 1159 between the two compositionally different layers is shown as a discrete transition in the figure, the interface between layers may have structure and / or interpenetration of the two layers that may create an intermediate compositionally distinct layer. In some embodiments this third layer may have a gradient composition between compositional layers 1156 and 1157.

[0068] Suitable Materials for Polymeric Foam Layers 350, 550, 654, 754, 850, and 954 of the Figures herein:

[0069] Polymeric foam layers for use herein are not particularly limited. Suitable polymeric foam layers for use herein may be easily identified by those skilled in the art in the light of the present disclosure.

[0070] According to an advantageous aspect, the polymeric foam layer for use herein comprises a material having a weight loss after 3 min at 600° C. of no greater than 70%, no greater than 60%, no greater than 50%, no greater than 40%, no greater than 30%, or even no greater than 25%, when measured according to the thermal stability test method described in the experimental section.

[0071] The types of polymeric foam layers as described above are typically referred to as thermally resistant materials or thermally resistant polymeric foam layers.

[0072] According to an exemplary aspect, the polymeric foam layer for use in the multilayer construction of the disclosure comprises a material selected from the group consisting of elastomeric materials, thermoplastic materials, thermoplastic elastomer materials, thermoplastic non-elastomeric materials, thermoset materials, and any combinations or mixtures thereof.

[0073] In one advantageous aspect, the polymeric foam layer for use herein comprises a material selected from the group consisting of silicone elastomers, fluorosilicone rubber, aromatic polyamides, polybenzimidazoles, polysulfides, polyimides, polysulfones, poly etherketones, fluorocarbons, polyisoprene, polybutadiene, polychloroprene, polyurethanes, polyolefins (in particular PE, PP and EVA), polystyrenes, and any combinations or mixtures thereof.

[0074] In a more advantageous aspect, the polymeric foam layer for use herein comprises a material selected from the group consisting of elastomeric materials.

[0075] In another more advantageous aspect, the polymeric foam layer for use herein reaches a compression value of at least 60% when using a compression force of no greater than 700 kPa, no greater than 600 kPa, no greater than 500 kPa, no greater than 400 kPa, no greater than 300 kPa, no greater than 250 kPa, no greater than 200 kPa, no greater than 150 kPa, no greater than 100 kPa, no greater than 80 kPa, no greater than 60 kPa, or even no greater than 50 kPa, when measured according to the compression test method described in the experimental section. This type of polymeric foam layers is typically referred to as (relatively highly) compressible polymeric foam layers (or soft polymeric foam layers).

[0076] In another more advantageous aspect, the polymeric foam layer for use herein comprises a material selected from the group consisting of silicone elastomers, in particular silicone rubbers, more in particular organopolysiloxane polymers.

[0077] In one particularly advantageous aspect of the disclosure, the polymeric foam layer for use herein is a silicone rubber foam layer.

[0078] According to an advantageous aspect, the silicone rubber foam layer for use herein is obtainable from a curable and foamable precursor of the silicone rubber foam layer, in particular an in-situ foamable precursor composition.

[0079] Precursor compositions of the silicone rubber foam for use herein are not particularly limited, as long as they are curable and foamable. Any curable and foamable precursors of a silicone rubber foam commonly known in the art may be formally used in the context of the present disclosure. Suitable curable and foamable precursors of a silicone rubber foam for use herein may be easily identified by those skilled in the art in the light of the present disclosure.

[0080] According to a more advantageous aspect, the precursor of the silicone rubber foam layer for use herein is a two-part composition.

[0081] In a typical aspect, the two-part precursor composition of the silicone rubber foam is selected from the group consisting of addition curing type two-part silicone compositions, condensation curing type two-part silicone compositions, and any combinations or mixtures thereof.

[0082] In a preferred aspect, the precursor of the silicone rubber foam for use herein comprises an addition curing type two-part silicone composition, in particular an addition curing type two-part organopolysiloxane composition.

[0083] Suitable addition curing type two-part organopolysiloxane compositions for use herein as the precursor of the silicone rubber foam may be easily identified by those skilled in the art. Exemplary addition curing type two-part organopolysiloxane compositions for use herein are described e.g. in U.S. Pat. No. 4,593,049 (Bauman et al.).

[0084] According to a particularly advantageous aspect of the present disclosure, the precursor of the silicone rubber foam for use herein comprises at least one organopolysiloxane compound A; at least one organohydrogenpolysiloxane compound B comprising at least two, in particular at least three hydrogen atoms per molecule; at least one hydroxyl containing compound C; an effective amount of a curing catalyst D, in particular a platinum-based curing catalyst; and optionally, a foaming agent.

[0085] In an exemplary aspect, the at least one organopolysiloxane compound A for use herein has the following formula: wherein:

[0086] R and R", are independently selected from the group consisting of Cito C20 hydrocarbon groups, and in particular R is an alkyl group chosen from the group consisting of methyl, ethyl, propyl, trifluoropropyl, and phenyl, and optionally R is a methyl group;

[0087] R' is a Ci to C20 alkenyl group, and in particular R' is chosen from the group consisting of vinyl, allyl, hexenyl, decenyl and tetradecenyl, and more in particular R' is a vinyl group;

[0088] R" is in particular an alkyl group such as a methyl, ethyl, propyl, trifluoropropyl, phenyl, and in particular R" is a methyl group; and n is an integer having a value in a range from 5 to 1000, and in particular from 5 to 100.

[0089] In another exemplary aspect, the at least one hydroxyl containing compound C for use herein is selected from the group consisting of alcohols, polyols in particular polyols having 3 to 12 carbon atoms and having an average of at least two hydroxyl groups per molecule, silanols, silanol containing organopolysiloxanes, silanol containing silanes, water, and any combinations or mixtures thereof.

[0090] In still another exemplary aspect, the at least one hydroxyl containing compound C for use herein is selected from the group consisting of silanol containing organopolysiloxanes.

[0091] According to one aspect of the present disclosure, the polymeric foam layer for use herein is obtainable by a process chemical foaming process which uses hydrogen generation from the presence of silanol and / or alcohol or water with excess siloxane having silicone hydride moieties and a platinum (0) catalyst, while at the same time a crosslinked network is formed by reaction of silicone containing vinyl groups with silicone hydride in a hydrosilylation reaction.

[0092] In some exemplary formulations of the polymeric foams of the present invention the polymeric foam is made from the crosslinking of siloxane polymers and the siloxane formulation contains additional additives which may be beneficial for a given application.

[0093] In a particular aspect of the disclosure, the polymeric foam layer for use herein further comprises an additive which is in particular selected from the group consisting of flame retardants, softeners, hardeners, filler materials, tackifiers, nucleating agents, colorants, pigments, conservatives, rheology modifiers (in particular aluminum hydroxide, magnesium hydroxide, magnesium carbonate, huntite, hydromagnesite, huntite-hydromagnesite, nesquehonite and calcium carbonate), UV-stabilizers, thixotropic agents, surface additives, flow additives, nanoparticles, antioxidants, reinforcing agents, toughening agents, silica particles, glass or synthetic fibers, thermally insulating particles, electrically conducting particles, electrically insulating particles, infrared opacifier particles, and any combinations or mixtures thereof.

[0094] In one beneficial aspect, the polymeric foam layer further comprises a non-flammable (or noncombusting) filler material. In a more beneficial aspect, the non-flammable filler material for use herein is selected from the group of inorganic fibers, in particular from the group consisting of mineral fibers, mineral wool, silicate fibers, ceramic fibers, glass fibers, carbon fibers, graphite fibers, asbestos fibers, aramide fibers, and any combinations or mixtures.

[0095] According to a more advantageous aspect, the non-flammable filler material for use herein is selected from the group consisting of mineral fibers, silicate fibers, ceramic fibers, asbestos fibers, aramide fibers, and any combinations or mixtures.

[0096] According to a particularly beneficial aspect, the non-flammable filler material for use herein is selected from the group consisting of mineral fibers. In the context of the present disclosure, it has indeed surprisingly been discovered that a polymeric foam (in particular silicone rubber foam) which further comprises mineral fibers are provided with excellent thermal resistance and thermal stability characteristics, as well as improved resistance to surface cracking and surface brittleness even after prolonged exposure to temperatures up to 600° C. Without wishing to be bound by theory, it is believed that these beneficial characteristics are due in particular to the excellent compatibility of the mineral fibers (in particular silicate fibers) with the surrounding polymeric matrix (in particular silicone polymer matrix), which participates in densifying and mechanically stabilizing the resulting matrix.

[0097] In a particular aspect of this execution, the non-flammable filler material for use herein is comprised in the polymeric foam in an amount ranging from 0.5 to 40 wt. %, from 1 to 30 wt. %, from 1 to 20 wt. %, from 1 to 10 wt. %, from 1 to 8 wt. %, from 2 to 8 wt. %, from 2 to 6 wt. %, or even from 3 to 6 wt. %, based on the overall weight of the precursor composition of the polymeric foam.

[0098] In some embodiments the silicone may further comprise closed shell glass bubbles having densities of less than about 0.5 g / cm3, or less than about 0.4 g / cm3or less than about 0.35 g / cm3or less than about 0.32 g / cm3, or even less than about 0.25 g / cm3, or less than about 0.2 g / cm3. Suitable glass bubbles can be sourced from manufacturers such as 3M Company (https: / / www.3m.eom / 3M / en_US / p / c / advanced-materials / glass-bubbles / )

[0099] In another typical aspect, the polymeric foam layer for use herein is free of thermally conductive fillers.

[0100] According to one advantageous aspect of the disclosure, the neat polymeric foam layer for use herein has a density no greater than 500 kg / m3, no greater than 450 kg / m3, no greater than 400 kg / m3, no greater than 380 kg / m3, no greater than 350 kg / m3, no greater than 320 kg / m3, no greater than 300 kg / m3, no greater than 280 kg / m3, no greater than 250 kg / m3, no greater than 220 kg / m3, or even no greater than 200 kg / m3, when measured according to the method described in the experimental section.

[0101] According to another advantageous aspect of the disclosure, the neat polymeric foam layer for use herein has a density in a range from 200 to 500 kg / m3, from 200 to 450 kg / m3, from 200 to 400 kg / m3, from 200 to 380 kg / m3, from 200 to 350 kg / m3, from 200 to 320 kg / m3, from 200 to 300 kg / m3, from 200 to 280 kg / m3, or even from 200 to 250 kg / m3, when measured according to the method described in the experimental section.

[0102] According to still another advantageous aspect of the disclosure, the neat polymeric foam layer for use herein has a hardness (Shore 00) greater than 10, greater than 15, greater than 20, greater than 25, greater than 30, greater than 40, or even greater than 50.

[0103] According to still another advantageous aspect of the disclosure, the neat polymeric foam layer for use herein has a hardness (Shore 00) in a range from 10 to 80, from 10 to 70, from 20 to 70, from 25 to 60, from 25 to 55, from 30 to 55, from 30 to 50, from 30 to 45, or even from 30 to 40. According to still another advantageous aspect of the disclosure, the neat polymeric foam layer for use herein has heat transfer time to 150° C. greater than 20 seconds, greater than 40 seconds, greater than 60 seconds, greater than 80 seconds, greater than 100 seconds, greater than 120 seconds, greater than 140 seconds, greater than 150 seconds, greater than 160 seconds, greater than 170 seconds, or even greater than 180 seconds, when measured according to the thermal insulation test method 1 described in the experimental section.

[0104] According to still another advantageous aspect of the disclosure, the neat polymeric foam layer for use herein has a heat transfer time to 150° C. in a range from 20 to 200 seconds, from 40 to 200 seconds, from 60 to 200 seconds, from 100 to 200 seconds, from 120 to 200 seconds, from 140 to 200 seconds, from 160 to 200 seconds, or even from 160 to 180 seconds, when measured according to the thermal insulation test method 1 described in the experimental section.

[0105] According to yet another advantageous aspect of the disclosure, the neat polymeric foam layer for use herein has a thermal conductivity no greater than 1 W / m K, no greater than 0.8 W / m K, no greater than 0.6 W / m K, no greater than 0.5 W / m K, no greater than 0.4 W / m K, no greater than 0.3 W / m K, no greater than 0.2 W / m K, no greaterthan 0.1 W / m K, no greater than 0.05 W / m K, or even no greater than 0.01 W / m K, when measured according to the test method described in the experimental section.

[0106] According to yet another advantageous aspect of the disclosure, the neat polymeric foam layer for use herein has a thermal conductivity in a range from 0.01 to 1 W / m K, from 0.05 to 1 W / m K, from 0.1 to 1 W / m K, from 0.2 to 1 W / m K, or even from 0.2 to 0.8 W / m K, when measured according to the test method described in the experimental section.

[0107] According to yet another advantageous aspect of the disclosure, the neat polymeric foam layer for use herein undergoes a ceramization process at a temperature no greater than 600° C., no greater than 550° C., no greaterthan 500° C., no greaterthan 450° C., no greater than 400° C., no greaterthan 350° C., no greater than 300° C., or even no greater than 250° C.

[0108] According to yet another advantageous aspect of the disclosure, the neat polymeric foam layer for use herein undergoes a ceramization process at a temperature in a range from 200° C. to 600° C., from 200° C. to 550° C., from 200° C. to 500° C., from 200° C. to 450° C., from 200° C. to 400° C., from 200° C. to 350° C., from 250° C. to 350° C., or even from 250° C. to 300° C.

[0109] In the context of the present disclosure, it has indeed surprisingly been discovered that a polymeric foam layer which has the ability to undergo a ceramization process, in particular at a relatively low temperature, is provided with excellent thermal resistance and thermal stability characteristics.

[0110] According to still another advantageous aspect of the disclosure, the neat polymeric foam layer for use herein has a V-0 classification, when measured according to the UL-94 standard flammability test method.

[0111] In one advantageous aspect, the neat polymeric foam layer for use herein has a thickness no greater than 10000 micrometers, no greater than 8000 micrometers, no greaterthan 6000 micrometers, no greater than 5000 micrometers, no greaterthan 4000 micrometers, no greater than 3000 micrometers, no greater than 2500 micrometers, no greater than 2000 micrometers, or even no greater than 1500 micrometers.

[0112] In another advantageous aspect, the neat polymeric foam layer for use herein has a thickness in a range from 100 to 10000 micrometers, from 100 to 8000 micrometers, from 100 to 6000 micrometers, from 200 to 5000 micrometers, from 300 to 5000 micrometers, from 300 to 4500 micrometers, from 300 to 4000 micrometers, from 500 to 4000 micrometers, from 500 to 3000 micrometers, from 500 to 2500 micrometers, from 500 to 2000 micrometers, from 500 to 1500 micrometers, from 800 to 1500 micrometers, or even from 1000 to 1500 micrometers.

[0113] According to one particular aspect of the disclosure, the polymeric foam layer for use herein may be provided with a first solid film or substrate which is permanently bonded to the foam layer. Such substrate may include but are not limited to polyesters, polyamides, polyimides, and other engineering polymeric substrates.

[0114] Suitable Materials for Inorganic layers 655, 755, and 955 of the Figures herein:

[0115] Thermally Resistant Barrier Layer (TRB from 3M):

[0116] The predominantly inorganic layer in multilayer cushioning constructions of the present disclosure may comprise one or more thermally resistant layers disposed on or adjacent to the thermally- insulating porous foam layer. The one or more thermally resistant layers are a single-layer of a dry-laid or wet-laid nonwoven fibrous thermal insulation (e.g., in the form of a mat, sheet, strip, or three- dimensional thin-walled structure) comprising a fiber matrix of ceramic or otherwise nonmetallic (i.e., not a metal, metal alloy, or metal composite) inorganic fibers, thermally insulative ceramic or otherwise nonmetallic (i.e., not a metal, metal alloy, or metal composite) inorganic particles dispersed evenly, uniformly, generally or otherwise throughout or to the extent permitted by the manufacturing process (e.g., there can be a little sedimentation of the particles on the bottom of the mat in both the dry laid and wet laid processes) within the fiber matrix, and an organic or inorganic binder (e.g., organic or inorganic adhesive binder, organic or inorganic binder fibers that are needle punched, stitched or otherwise mechanically entangled into the fiber matrix so as to hold together the fiber matrix, etc.) dispersed evenly, uniformly, generally or otherwise throughout or to the extent permitted by the manufacturing process within the fiber matrix so as to bond together the inorganic filler particles and inorganic fibers or otherwise hold together the fiber matrix for as long as needed to at least survive the degree of handling required (e.g,. during the encapsulation process) before being installed between battery cells. Detailed description of such material can be found in Patent Publication, WO2023 / 248133 Al. Other similar types of materials based on aerogel materials are also suitable for the inorganic layer.

[0117] Thin Glass Layer:

[0118] Additional inorganic layers or alternative inorganic layers may include the combination of a thin Mica composite layer along with a TRB layer or as a stand alone layer. Another inorganic layer which can provide beneficial blast performance (torch and grit) is thin glass. The thickness may be in a range from 20 micrometers to 250 micrometers, or from 25 micrometers to than 150 micrometers, or from 50 micrometers to 100 micrometers. Suppliers of thin transparent glass include Coming, Nippon Electric Glass, Schott and Asahi Glass. ic layers:

[0119] Other material may also be suitable for the predominantly inorganic layer as well. Such layers may include but are not limited to ceramic layers, metal oxide layers, for example alumina and other woven ceramic and or woven inorganic glass layers.

[0120] One other class of material that may be useful are ablative highly fdled silicone materials, which are designed to be used in blast environments. These materials are designed as solid highly inorganic fdled polysiloxanes which protect against high heat, direct and indirect flame, and erosion in aerospace, defense, and industrial applications.

[0121] EXEMPLARY EMBODIMENTS

[0122] 1. An article, comprising:

[0123] • a first polymeric foam base layer comprising a crosslinked elastomeric material, wherein the polymeric foam base layer has a first major surface, a second major surface opposite the first major surface,

[0124] • a first set of structures extending outwardly in a repeating pattern from the first major surface of the base layer in the thickness direction,

[0125] • a predominantly inorganic layer adjacent, preferably immediately adjacent, to the second major surface of the base layer, wherein the first set of structures are made of the crosslinked elastomeric material.

[0126] 2. An article, comprising:

[0127] • a first polymeric foam base layer comprising a crosslinked elastomeric material, wherein the polymeric foam base layer has a first major surface, a second major surface opposite the first major surface,

[0128] • a first set of structures extending outwardly in a repeating pattern from the first major surface of the base layer in the thickness direction, wherein the first set of structures are made of the crosslinked elastomeric material.

[0129] 3. An article, comprising:

[0130] • a polymeric base layer comprising a crosslinked elastomeric material, wherein the polymeric base layer has a first major surface, a second major surface opposite the first major surface,

[0131] • a first set of structures extending outwardly in a repeating pattern from the first major surface of the base layer in the thickness direction,

[0132] • a predominantly inorganic layer adjacent, preferably immediately adjacent, to the second major surface of the base layer, wherein the first set of structures are made of the crosslinked elastomeric material. article, comprising:

[0133] • a first polymeric foam base layer comprising a crosslinked elastomeric material, wherein the first polymeric foam base layer has a first major surface and a second major surface opposite the first major surface,

[0134] • a first set of structures extending outwardly in a repeating pattern from the first major surface of the base layer in the thickness direction,

[0135] • a second set of structures extending outwardly in a repeating pattern from the second major surface of the base layer in a direction opposite from the direction of the first set of structures, wherein the first and second sets of structures are made of crosslinked elastomeric material. article, comprising:

[0136] • a first polymeric foam base layer comprising a crosslinked elastomeric material, wherein the first polymeric foam base layer has a first major surface and a second major surface opposite the first major surface,

[0137] • a first set of structures extending outwardly in a repeating pattern from the first major surface of the base layer in the thickness direction,

[0138] • a predominantly inorganic layer adjacent, preferably immediately adjacent, to the second major surface of the first base layer,

[0139] • a second polymeric foam base layer comprising a crosslinked elastomeric material, wherein the second polymeric foam base layer has a first major surface and a second major surface opposite the first major surface, wherein the first major surface of the second polymeric foam base layer is adjacent, preferably immediately adjacent, the predominantly inorganic layer,

[0140] • a second set of structures extending outwardly in a repeating pattern from the second major surface of the second base layer in a direction opposite from the direction of the first set of structures, wherein the first and second sets of structures are made of crosslinked elastomeric material. article, comprising:

[0141] • an polymeric foam base layer comprising a crosslinked elastomeric material, wherein the polymeric foam base layer has a first major surface, a second major surface opposite the first major surface,

[0142] • a first set of structures extending outwardly in a repeating pattern from the first major surface of the base layer in the thickness direction,

[0143] • a predominantly inorganic layer adjacent, preferably immediately adjacent, to the second major surface of the base layer, wherein the first set of structures are made of solid material (non-foamed).

[0144] Structures and base layers made of different materials

[0145] 7. An article, comprising:

[0146] • an polymeric foam base layer comprising a crosslinked elastomeric material, wherein the polymeric foam base layer has a first major surface, a second major surface opposite the first major surface,

[0147] • a first set of structures extending outwardly in a repeating pattern from the first major surface of the base layer in the thickness direction,

[0148] • a predominantly inorganic layer adjacent, preferably immediately adjacent, to the second major surface of the base layer, wherein the first set of structures are made of a crosslinked elastomeric material different from the crosslinked elastomeric material of the base layer.

[0149] 8. An article according to any of the preceding embodiments, wherein the crosslinked elastomeric material is a foamed material chosen from silicone, polyurethane, and polyamides, preferably silicone.

[0150] 9. An article according to any of the preceding embodiments, wherein the article further comprises a substrate layer.

[0151] 10. An article according to any of the preceding embodiments, wherein the article further comprises a substrate layer immediately adjacent the second surface of the base layer.

[0152] 11. An article according to any of the preceding embodiments, wherein the article further comprises a substrate layer bonded to the second surface of the base layer.

[0153] 12. An article according to any of the preceding embodiments, wherein the article further comprises an encapsulating layer surrounding the other elements of the article.

[0154] 13. An article according to any of the preceding embodiments, wherein the article further comprises a substrate layer bonded to both the first polymeric base layer and the second polymeric base layer.

[0155] 14. An article according to any of the preceding embodiments, wherein the predominantly inorganic layer comprises one or more thermally resistant layers.

[0156] 15. An article according to any of the preceding embodiments, wherein the predominantly inorganic layer comprises one or more thermally resistant layers, and wherein the one or more thermally resistant layers are a single-layer of a dry-laid or wet-laid nonwoven fibrous thermal insulation.

[0157] 16. An article according to any of the preceding embodiments, wherein the predominantly inorganic layer comprises thermally insulative ceramic or otherwise nonmetallic inorganic particles. An article according to any of the preceding embodiments, wherein the predominantly inorganic layer comprises or is chosen from glass layers, mica layers, ceramic layers, metal oxide layers, woven ceramic layers, and woven inorganic glass layers. An article according to any of the preceding embodiments, wherein the article further comprises an adhesive layer and optionally a liner immediately adjacent the adhesive layer. An article according to any of the preceding embodiments, wherein the structures for the first set and / or second set (when present) are chosen independently of each other, and are prisms with a cross section having a shape chosen from triangular, truncated triangular (or trapezoid), square, rectangular, and a shape defined by a cubic Bezier function (e.g., dome shape, and bullet-like shape) preferably a truncated triangular shape. An article according to any of the preceding embodiments, wherein the structures for the first set and / or second set (when present) are chosen independently of each other, and are prisms with a cross section having a shape chosen from triangular, truncated triangular (or trapezoid), square, rectangular, and a shape defined by a cubic Bezier function (e.g., dome shape, and bullet-like shape) preferably a truncated triangular, wherein adjacent prisms are not touching each other. An article according to any of the preceding embodiments, wherein the structures for the first set and the second set are chosen independently of each other, and are prisms with a cross section having a shape chosen from triangular, truncated triangular, square, rectangular, a shape defined by a cubic Bezier function (e.g., dome shape, and bullet-like shape); and wherein the cross sectional shapes of the first set of structures are the same as the cross sectional shapes of the second set of the structures. An article according to any of the preceding embodiments, wherein the structures for the first set and the second set are chosen independently of each other, and are prisms with a cross section having a shape chosen from triangular, truncated triangular, square, rectangular, a shape defined by a cubic Bezier function (e.g., dome shape, and bullet-like shape); and wherein the cross sectional shapes of the first set of structures are different from the cross sectional shapes of the second set of the structures. An article according to any of the preceding embodiments, wherein the structures for the first set and / or second set (when present) are chosen independently of each other, and are prisms with a cross section having a shape chosen from triangular, truncated triangular (or trapezoid), square, rectangular, and a shape defined by a cubic Bezier function (e.g., dome shape, and bullet-like shape) preferably a truncated triangular, wherein the width (base) of the structures is Pi, wherein the wherein the distance between two contiguous prisms is the pitch, P2, and wherein the ratio of P2 / Pi is from 1 to about 10, or from about 2 to about 8, or from about 2 to about 6, or from about 2 to about 4.

[0158] 24. An article according to any of the preceding embodiments, wherein the first set of structures and / or the second set of structures (when present) comprise two or more different types of structures with each set.

[0159] 25. An article according to any of the preceding embodiments, wherein the first set of structures and / or the second set of structures, independently from each other, comprise two or more different types of structures, and wherein the difference between the structures are chosen from differences in cross- sectional shape, and differences in spacing between the structures.

[0160] 26. An article according to any of the preceding embodiments, wherein the first set of structures and the second set of structures are different from each other with respect to the composition.

[0161] 27. An article according to any of the preceding embodiments, wherein the crosslinked elastomeric material of the first base layer (and / or the second base layer when present) and the material of the first set of structures and / or the second set of structures (when present) is the same.

[0162] 28. An article according to any of the preceding embodiments, wherein the total thickness (h2) of the base layer plus the height of structures on the base layer ranges from 100 to 10000 micrometers, from 100 to 8000 micrometers, from 100 to 6000 micrometers, from 200 to 5000 micrometers, from 300 to 5000 micrometers, from 300 to 4500 micrometers, from 300 to 4000 micrometers, from 500 to 4000 micrometers, from 500 to 3000 micrometers, from 500 to 2500 micrometers, from 500 to 2000 micrometers, from 500 to 1500 micrometers, from 800 to 1500 micrometers, or even from 1000 to 1500 micrometers.

[0163] 29. An article according to any of the preceding embodiments, wherein a set of structures (first or second set, each with the ratios below chosen independently from each other) has a height hi and the article has a total height 112, wherein the ratio of hi / t ranges from about 0.03 to about 0.65, or from about 0.05 to about 0.6, or from about 0. 1 to about 0.6 or from about 0.2 to about 0.5, or from about 0.25 to about 0.5.

[0164] 30. An article according to any of the preceding embodiments, wherein a set of structures (first or second set, each with the ratios below chosen independently from each other) has a height hi and the article has a total height I12, wherein the ratio of hi / h2 ranges from about 0.05 to about 0.95, or from about 0.1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95.

[0165] 31. An article according to any of the preceding embodiments, wherein a set of structures (first or second set, each with the ratios below chosen independently from each other) has a height hi and the article has a total height I12, wherein the ratio of hi / h2 ranges from about 0.05 to about 0.95, or from about 0.1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95, wherein the width (base) of the structures is Pi, wherein the distance between two contiguous prisms is the pitch, P2, and wherein the ratio of P2 / Pi is from 1 to about 10, or from about 2 to about 8, or from about 2 to about 6, or from about 2 to about 4.

[0166] 32. An article according to any of the preceding embodiments, wherein a set of structures (first or second set, each with the ratios below chosen independently from each other) has a height hi and the article has a total height I12, wherein the ratio of hi / t^ ranges from about 0.03 to about 0.65, or from about 0.05 to about 0.6, or from about 0.1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.25 to about 0.5, wherein the width (base) of the structures is Pi, wherein the distance between two contiguous prisms is the pitch, P2, and wherein the ratio of P2 / Pi is from 1 to about 10, or from about 2 to about 8, or from about 2 to about 6, or from about 2 to about 4.

[0167] 33. An article according to any of the preceding embodiments, wherein a set of structures (first or second set, each with the ratios below chosen independently from each other) has a height hi, wherein the width (base) of the structures is Pi, and wherein ratio hi / Pi from 6: 1 to 0.5: 1, from 5: 1 to 0.5: 1, or from 4: 1 to 0.5: 1.

[0168] 34. An article according to any of the preceding embodiments, wherein the article has a first set of structures with a height hi, and a second set of structures with a height I14, and the article has a total height I12, wherein the ratio of hi / h2 ranges from about 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0. 1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.2 to about 0.4 and wherein the ratio of hi / lv ranges from about 0.03 to about 0.65, or from 0.05 to about 0.6, or from about 0. 1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.2 to about 0.4.

[0169] 35. An article according to any of the preceding embodiments, wherein the article has a first set of structures with a height hi, and a second set of structures with a height I14, and the article has a total height I12, wherein the ratio of hi / h2 ranges from about 0.05 to about 0.95, or from about 0.1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95, and wherein the ratio of 114 / 112 ranges from about 0.05 to about 0.90, or from about 0.1 to about 0.90, or from about 0.5 to about 0.90 or from about 0.7 to about 0.90.

[0170] 36. An article according to any of the preceding embodiments, wherein the height of the first set of structures and / or the second set of structures hi ranges, independently for each set, from 100 microns to 6 mm, preferably from 500 microns to 4mm.

[0171] 37. An article according to any of the preceding embodiments, wherein the surface of the second surface of the base layer is substantially flat.

[0172] 38. An article according to any of the preceding embodiments, wherein the first set of structures and / or the second set of structures are chosen, independently of each other, from trapezoid prisms having a trapezoid cross section, which has: (a) two bases: a long base and a short base, (b) two non-parallel sides (legs), wherein the long base is aligned with the corresponding major surface of the base layer, (c) a height hi of the trapezoid, defined as the distance between the long base and the short base along a line perpendicular to both the long base and the short base. An article according to any of the preceding embodiments, wherein the first set of structures and / or the second set of structures are chosen, independently of each other, from trapezoid prisms having a trapezoid cross section, which has: (a) two bases: a long base and a short base, (b) two non-parallel sides (legs), wherein the long base is aligned with the corresponding major surface of the base layer, (c) a height hi of the trapezoid, defined as the distance between the long base and the short base along a line perpendicular to both the long base and the short base, where the length of the long base of the trapezoid (width of the structure) is from 0. 1 to 2 mm , the length of the short base of the trapezoid is from 0.25 to 2 mm and the height hi is from 0.25 mm to 7 mm. An article according to any of the preceding embodiments, wherein the first set of structures and / or the second set of structures are chosen, independently of each other, from trapezoid prisms having a trapezoid cross section, which has: (a) two bases: a long base and a short base, (b) two non-parallel sides (legs), wherein the long base is aligned with the corresponding major surface of the base layer, (c) a height hi of the trapezoid, defined as the distance between the long base and the short base along a line perpendicular to both the long base and the short base, where the distance between two contiguous prisms (pitch, P2) is from 0.25 mm-10 mm, preferably from 0.25 mm-8 mm. An article according to any of the preceding embodiments, wherein the first set of structures and / or the second set of structures are chosen, independently of each other, from trapezoid prisms having a trapezoid cross section, which has: (a) two bases: a long base and a short base, (b) two non-parallel sides (legs), wherein the long base is aligned with the corresponding major surface of the base layer, (c) a height hi of the trapezoid, defined as the distance between the long base and the short base along a line perpendicular to both the long base and the short base, where the wherein the height hi is from 0.1 mm-5 mm, 0.25- mm, 0.25-3 mm. An article according to any of the preceding embodiments, wherein the first set of structures comprise two different types of structures, prisms A and prisms B, each type chosen, independently of each other, from trapezoid prisms having trapezoid cross sections of different dimensions, wherein each set of structures has: (a) two bases: a long base and a short base, (b) two non-parallel sides (legs), wherein the long base is aligned with the corresponding major surface of the base layer, (c) a height hi of the trapezoid, defined as the distance between the long base and the short base along a line perpendicular to both the long base and the short base, wherein prisms A and prisms B alternate with each other along a linear dimension of the base layer, wherein the width of the base of prisms A is wider than the width of the base of prisms B, and wherein the height of prisms A is higher than the height of prisms B. 43. An article according to any of the preceding embodiments, wherein the first set of structures comprise two different types of structures, prisms A and prisms B, each type chosen, independently of each other, from trapezoid prisms having trapezoid cross sections of different dimensions, wherein each set of structures has: (a) two bases: a long base and a short base, (b) two non-parallel sides (legs), wherein the long base is aligned with the corresponding major surface of the base layer, (c) a height hi of the trapezoid, defined as the distance between the long base and the short base along a line perpendicular to both the long base and the short base, wherein prisms A and prisms B alternate with each other along a linear dimension of the base layer.

[0173] 44. An article according to any of the preceding embodiments, wherein the first set of structures comprise two different types of structures, prisms A and prisms B, each type chosen, independently of each other, from trapezoid prisms having trapezoid cross sections of different dimensions, wherein each set of structures has: (a) two bases: a long base and a short base, (b) two non-parallel sides (legs), wherein the long base is aligned with the corresponding major surface of the base layer, (c) a height hi of the trapezoid, defined as the distance between the long base and the short base along a line perpendicular to both the long base and the short base, wherein prisms A and prisms B alternate with each other along a linear dimension of the base layer, and wherein the width of the base of prisms A is from 0.25 mm to 2 mm, and the width of the base of prisms B is from 0.25 mm to 2 mm, and wherein the height of prisms A is from 0.5 mm to 4.0 mm, and the height of prisms B is from 0.5 mm to 4.0 mm.

[0174] 45. An article according to any of the preceding embodiments, wherein the crosslinked elastomeric material comprises a filler.

[0175] 46. An article according to any of the preceding embodiments, wherein the crosslinked elastomeric material comprises a filler chosen from particles, fibers, and combinations thereof.

[0176] 47. An article according to any of the preceding embodiments, wherein the crosslinked elastomeric material comprises a filler chosen from particles, fibers, and combinations thereof, wherein the filler is chosen from mineral fibers, silicate fibers, glass or synthetic fibers ceramic fibers, asbestos fibers, aramide fibers, closed shell glass bubbles, silica particles, thermally insulating particles, electrically conducting particles, electrically insulating particles, and combinations thereof.

[0177] 48. An article according to any of the preceding embodiments, wherein the article comprises a filler from 0.5 to 40 wt %, preferably from 1 to 30 wt % based on the total weight of a precursor composition of the crosslinked polymeric material.

[0178] 49. An article according to any of the preceding embodiments, wherein the article comprises glass bubbles having densities of less than about 0.5 g / cm3, or less than about 0.4 g / cm3or less than about 0.35 g / cm3or less than about 0.32 g / cm3, or even less than about 0.25 g / cm3, or less than about 0.2 g / cm3.

[0179] 50. An article according to any of the preceding embodiments, wherein the compression force to deflection at 25% strain is greater than 20 KPa and at 50% strain is less than 400KPa under the CFD test.

[0180] 51. An article according to any of the preceding embodiments, wherein the compression force to deflection at 25% strain is greater than 50 KPa and at 50% strain is less than 400KPa under the CFD test.

[0181] 52. An article according to any of the preceding embodiments, wherein the compression force to deflection at 25% strain is greater than 50 KPa and at 50% strain is less than 200KPa under the CFD test.

[0182] 53. An article according to any of the preceding embodiments, wherein the structured polymeric foam material has a thermal conductivity from 0.05 W / (m*K) to 0.6 W / (m*K) as measured according to the Thermal Conductivity Test.

[0183] 54. An article according to any of the preceding embodiments, wherein the crosslinked elastomeric material has a density from 0.15 g / cm3to 0.8 g / cm3, and wherein the structured polymeric foam material has a bulk density from 0.1 g / cm3to 0.6 g / cm3, from 0.1 g / cm3to 0.5 g / cm3, or from 0.1 g / cm3to 0.4 g / cm3.

[0184] 55. A battery module comprising at least two battery cells and an article according to any of the preceding embodiments.

[0185] EXPERIMENTAL SECTION

[0186] Table 1: Materials

[0187] Preparatory example 1 : Silicone formulation Part A used for example 2 and example 3

[0188] To prepare Part A, 7.5% weight percent of S38XS Glass microspheres were compounded into Elkem 3242 A in a size 1000 speed mixer cup. Fillers were weighed into speedmixer cup and wetted by the silicone fluid prior to mixing. The mixture was prepared using a DAC-600 SpeedMixer (Flacktek, Landrum, S.C.) at 2000 rpm for 1-2 minutes to provide a well-dispersed resin blend.

[0189] Preparatory example 2: Silicone formulation Part B used for example 2 and example 3

[0190] To prepare Part B, 15% weight percent of S38XS Glass microspheres were compounded into Elkem 3242 B in a size 1000 speed mixer cup. Fillers were weighed into speedmix cups and wetted by the silicone fluid prior to mixing. The mixture was prepared using a DAC-600 SpeedMixer (Flacktek, Landrum, S.C.) at 2000 rpm for 1-2 minutes to provide a well-dispersed resin blend.

[0191] Preparatory example 3: Silicone formulation Part A used for example 13 through example 22

[0192] To prepare Part A, 230.76 g of SB-342, 17.11 g of CF-50 and 341.86 g of Elkem 3242 A were mixed in a size 1000 speed mixer cup. The fdlers were weighed into speedmixer cup and wetted by the silicone fluid prior to mixing. The mixture was prepared using a DAC-600 SpeedMixer (Flacktek, Landrum, S.C.) at 2000 rpm for 1-2 minutes to provide a well-dispersed resin blend. After mixing, 10.27 g of Aerosil 812S was added to the mixture and the mixture was speed mixed at 2000 rpm for 1 minute increments 2 times to provide a well-dispersed resin blend.

[0193] Preparatory example 4: Silicone formulation Part B used for example 13 through example 22

[0194] To prepare Part B, 254.73 g of calcium carbonate and 335.20 g Elkem 3242 B were mixed in a size 1000 speed mixer cup. The fillers were weighed into speedmixer cup and wetted by the silicone fluid prior to mixing. The mixture was prepared using a DAC-600 SpeedMixer (Flacktek, Landrum, S.C.) at 2000 rpm for 1-2 minutes to provide a well-dispersed resin blend. After mixing, 10.08 g of Aerosil 812S was added to the mixture and the mixture was speed mixed at 2000 rpm for 1 minutes 2 times to provide a well-dispersed resin blend.

[0195] Preparatory example 5: UV curable silicone resin

[0196] To prepare UV curable silicone resin, 90 g ofVQM-135 and 4.50 g of Dow Coming Syloff-7678 was added into a size 100 speed mixer cup. The resins were mixed in a Flaktek DAC 150 FV. 1 speedmixer at 3000 rpm for 1 minute to provide a clear, colorless homogeneous resin. A catalyst solution of 151.3 mg of (Trimethyl)methylcyclopentadienylplatinum(IV) dissolved in 2.33 mL of toluene was prepared in a small amber vial. To the speed mixer cup was added 35.7 microliters of the platinum catalyst solution (~15ppm Pt metal relative to the silicone resin). The resin was then mixed in the absence of UV and blue light in the speed mixer for another 1 minute cycle at 3000 rpm. The UV curable silicone is stable in the absence of UV and blue light.

[0197] Comparative Example 1 : CE 1

[0198] Into a size 40 speed mixer cup was added ~30 g of 2: 1 mixture by weight of preparatory example 1 (Part A) and preparatory example 2 (Part B) respectively. The silicone was mixed at 1200 rpm for 0.5 min. The mixture was coated between two non-silicone, non-fluorinated (NSNF) release liners with a coating gap of ~8 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the liners were removed and discarded. The resulting fdm having two planar major surfaces had a thickness of 0.972 mm and density of 0.228 g / cm3.

[0199] Example 1: Ex 1

[0200] Into a size 40 speed mixer cup was added ~30 g of 2: 1 mixture by weight of preparatory example 1 (Part A) and preparatory example 2 (Part B) respectively. The silicone was mixed at 1200 rpm for 0.5 min. The mixture was coated between a square wave prism fdm tool, with approximately 90 um by 30 um rectangular features that are spaced at approximately 30 um intervals, and a planar non-silicone, nonfluorinated release liner. A handspread coating was made using a flatbed coater with a comma bar where the coating was made between the fdm tool and the NSNF liner. The gap for the coating excluding fdm tool and liner was 20 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the liner and fdm tool were removed and discarded. The resulting fdm had a thickness of 2.74 mm and density of 0.236 g / cm3. Samples of microreplicated tooling and structured foams were prepared for imaging with electron microscopy (SEM) via cross sectioning with a razor blade through the thickness of the materials and mounting edge on a supporting fixture. Figure 12A and 12B show cross sectional micrographs of microreplicated tooling and the resulting structured foams.

[0201] Example 2: Ex 2

[0202] Into a size 40 speed mixer cup was added ~30 g of 2: 1 mixture by weight of preparatory example 1 (Part A) and preparatory example 2 (Part B) respectively. The silicone was mixed at 1200 rpm for 0.5 min. The mixture was coated between a triangular wave fdm tool, where features have a base dimension of approximately 360 um and height of 180 um, oriented edge to edge (no spacing), and a planar non- silicone, non-fluorinated release liner. A handspread coating was made using a flatbed coater with a comma bar where the coating was made between the fdm tool and the NSNF liner. The gap for the coating excluding fdm tool and liner was 17 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the liner and fdm tool were removed and discarded. The resulting fdm had a thickness of 2.918 mm and density of 0.219 g / cm3. Samples of microreplicated tooling and structured foams were prepared for imaging with electron microscopy (SEM) via cross sectioning with a razor blade through the thickness of the materials and mounting edge on a supporting fixture. Figure 13A and 13B show cross sectional micrographs of microreplicated tooling and the resulting structured foams.

[0203] Thermal conductivity of the comparative example 1 (CE1) and the structured foams of examples 1 and 2 were measured with a TA Instruments Fox 50 Heat Flow Meter. 2 inch diameter circular discs were punched out of each foam sample. The top platen temperature was set to 70°C and the bottom platen was set to 50°C. A platen pressure of 25 psi was applied to the compress the foam between the platens. Once the top and bottom platens reach temperature setpoint, the platen displacement and thermal flux are measured repeatedly until reaching equilibrium. A thermal conductivity is reported at equilibrium based on the sample dimensions. Table 2A reports thermal conductivity results for the control, CE1, and the two structured foams, examples 1 and 2. A percentage change in thermal conductivity of the structured foams relative to the control is also reported.

[0204] Compression force deflection (CFD) measurements were measured on the foams. 50.8 mm diameter circular discs were punched out of each foam sample. Samples were loaded between parallel platens in an Instron Model 5581 with a 5kN load cell. Compressive load was recorded for three consecutive compressions from 0-90% strain with a constant displacement of 1 mm / minute. Test followed TMAE No.: 1034 with a modified preload of 725 Pa. The 3rd cycle was used for evaluation and reported in Table 2B for each of the foams.

[0205] Table 2A: Thermal Conductivity

[0206] Table 2B: Stress from 3rdloading cycle of compression force deflection (kPa)

[0207] Figures 14A-14E and Figures 15A-15E show experimental structures which represent prism structures described in Figures 8A and 8B where there are spaces between structures. Table 3 shows results of theoretical calculated thermal conductivity improvements for foams with these structures based on the varying amounts of additional free volume provided by various spacing between structures. Structures shown in Fig. 14A, Fig. 14B, Fig. 14C, Fig. 14D and Fig 14E are Example 3, Example 4, Example 5, Example 6 and Example 7 respectively. Structures shown in Fig. 15A, Fig. 15B, Fig. 15C, Fig. 15D and Fig 15E are Example 8, Example 9, Example 10, Example 11 and Example 12 respectively.

[0208] Table 3: Thermal conductivity calculations for Example 1-12, percent improvement vs. CE 1

[0209] Comparative Example 2: CE 2

[0210] Into a size 40 speed mixer cup was added -35.02 g of preparatory example 3 (Part A) and 9.42 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between a 2mil M64K7 silicone coated liner from Mitsubishi and a 2 mil unprimed PET layer with a coating gap of 24.5 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the PET liner was removed and discarded. The M64K7 liner bonded permanently to the silicone. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of 1.998 mm and a density of 0.48 g / cm3.

[0211] Examples 13-22:

[0212] Examples 13-22 utilized patterned metal tooling made using the cross sectional profdes of the patterns shown in figures 14A-E and figures 15A-D. Each tool was made by cutting linear grooves at the repeat dimensions shown in the figures 14 and 15, where the linear grooves extend in one direction extending the length of the tooling plate. Each metal tool had dimensions of approximately 10 inches by 10 inches square. All coating were made by casting the silicone resin between the tool and a liner or substrate film where the linear grooves were oriented in the direction of the coating direction. All tools were treated with a release treatment so that the silicone coating could be removed from the tools.

[0213] Example 13: Ex 13

[0214] Into a size 40 speed mixer cup was added -34.99 g of preparatory example 3 (Part A) and 9.51 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between a metal tool treated for release with the structure shown in Fig. 14A and a 2mil M64K7 silicone coated liner from Mitsubishi with a coating gap of 22 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the silicone foam was removed from the tool and the PET liner was permanently bonded to the non-structured side of the silicone foam. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of 2.026 mm and a bulk density of 0.44 g / cm3. A sample of the resulting structured foam was prepared for imaging with optical microscopy via cross sectioning with a razor blade through the thickness of the materials and mounting the sample edge on a supporting fixture. The optical micrograph can be seen in Fig. 16A where the white scale bar represents 400 microns.

[0215] Example 14: Ex 14

[0216] Into a size 40 speed mixer cup was added -35.10 g of preparatory example 3 (Part A) and 9.44 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between a metal tool treated for release with the structure shown in Fig. 14B and a 2mil M64K7 silicone coated liner from Mitsubishi with a coating gap of 22 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the silicone foam was removed from the tool and the PET liner was permanently bonded to the non-structured side of the silicone foam. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of 2.004 mm and a bulk density of 0.45 g / cm3. A sample of the resulting structured foam was prepared for imaging with optical microscopy via cross sectioning with a razor blade through the thickness of the materials and mounting the sample edge on a supporting fixture. The optical micrograph can be seen in Fig. 16A where the white scale bar represents 400 microns.

[0217] Example 15: Ex 15

[0218] Into a size 40 speed mixer cup was added -35.08 g of preparatory example 3 (Part A) and 9.50 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between a metal tool treated for release with the structure shown in Fig. 14C and a 2mil M64K7 silicone coated liner from Mitsubishi with a coating gap of 15 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the silicone foam was removed from the tool and the PET liner was permanently bonded to the non-structured side of the silicone foam. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of 2.004 mm and a bulk density of 0.41 g / cm3. A sample of the resulting structured foam was prepared for imaging with optical microscopy via cross sectioning with a razor blade through the thickness of the materials and mounting the sample edge on a supporting fixture. The optical micrograph can be seen in Fig. 16A where the white scale bar represents 400 microns.

[0219] Example 16: Ex 16

[0220] Into a size 40 speed mixer cup was added -35.10 g of preparatory example 3 (Part A) and 9.49 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between a metal tool treated for release with the structure shown in Fig. 14D and a 2mil M64K7 silicone coated liner from Mitsubishi with a coating gap of 15.5 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the silicone foam was removed from the tool and the PET liner was permanently bonded to the non-structured side of the silicone foam. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of 2.086 mm and a bulk density of 0.39 g / cm3. A sample of the resulting structured foam was prepared for imaging with optical microscopy via cross sectioning with a razor blade through the thickness of the materials and mounting the sample edge on a supporting fixture. The optical micrograph can be seen in Fig. 16A where the white scale bar represents 400 microns.

[0221] Example 17: Ex 17

[0222] Into a size 40 speed mixer cup was added -35.18 g of preparatory example 3 (Part A) and 9.46 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between a metal tool treated for release with the structure shown in Fig. 14E and a 2mil M64K7 silicone coated liner from Mitsubishi with a coating gap of 14.5 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the silicone foam was removed from the tool and the PET liner was permanently bonded to the non-structured side of the silicone foam. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of 1.948 mm and a bulk density of 0.41 g / cm3. A sample of the resulting structured foam was prepared for imaging with optical microscopy via cross sectioning with a razor blade through the thickness of the materials and mounting the sample edge on a supporting fixture. The optical micrograph can be seen in Fig. 16A where the white scale bar represents 400 microns.

[0223] Example 18: Ex 18

[0224] Into a size 40 speed mixer cup was added -35.04 g of preparatory example 3 (Part A) and 9.46 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between a metal tool treated for release with the structure shown in Fig. 15 A and a 2mil M64K7 silicone coated liner from Mitsubishi with a coating gap of 15 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the silicone foam was removed from the tool and the PET liner was permanently bonded to the non-structured side of the silicone foam. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of 1.978 mm and a bulk density of 0.41 g / cm3. A sample of the resulting structured foam was prepared for imaging with optical microscopy via cross sectioning with a razor blade through the thickness of the materials and mounting the sample edge on a supporting fixture. The optical micrograph can be seen in Fig. 16B where the white scale bar represents 400 microns.

[0225] Example 19: Ex 19

[0226] Into a size 40 speed mixer cup was added -35.13 g of preparatory example 3 (Part A) and 9.46 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between a metal tool treated for release with the structure shown in Fig. 15B and a 2mil M64K7 silicone coated liner from Mitsubishi with a coating gap of 16 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the silicone foam was removed from the tool and the PET liner was permanently bonded to the non-structured side of the silicone foam. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of 2.066 mm and a bulk density of 0.42 g / cm3. A sample of the resulting structured foam was prepared for imaging with optical microscopy via cross sectioning with a razor blade through the thickness of the materials and mounting the sample edge on a supporting fixture. The optical micrograph can be seen in Fig. 16B where the white scale bar represents 400 microns.

[0227] Example 20: Ex 20

[0228] Into a size 40 speed mixer cup was added -35.02 g of preparatory example 3 (Part A) and 9.57 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between a metal tool treated for release with the structure shown in Fig. 15C and a 2mil M64K7 silicone coated liner from Mitsubishi with a coating gap of 10.5 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the silicone foam was removed from the tool and the PET liner was permanently bonded to the non-structured side of the silicone foam. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of 2.054 mm and a bulk density of 0.39 g / cm3. A sample of the resulting structured foam was prepared for imaging with optical microscopy via cross sectioning with a razor blade through the thickness of the materials and mounting the sample edge on a supporting fixture. The optical micrograph can be seen in Fig. 16B where the white scale bar represents 400 microns.

[0229] Example 21: Ex 21

[0230] Into a size 40 speed mixer cup was added -35.02 g of preparatory example 3 (Part A) and 9.46 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between a metal tool treated for release with the structure shown in Fig. 15D and a 2mil M64K7 silicone coated liner from Mitsubishi with a coating gap of 10.5 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the silicone foam was removed from the tool and the PET liner was permanently bonded to the non-structured side of the silicone foam. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of 1.996 mm and a bulk density of 0.36 g / cm3. A sample of the resulting structured foam was prepared for imaging with optical microscopy via cross sectioning with a razor blade through the thickness of the materials and mounting the sample edge on a supporting fixture. The optical micrograph can be seen in Fig. 16B where the white scale bar represents 400 microns.

[0231] Figure 17A shows compression force deflection (CFD) data for examples 13 to 17 in comparison to comparative example, CE 2. If can clearly be seen that changes in the size of the structures of the foams as well as the pitch of the structures leads to changes and extension of the flat regions of the CFD curves. Similarly, Figure 17B, shows compression force deflection data for examples 18 to 21 in comparison to comparative example, CE 2. Again, it is seen that changes in the size of the structures of the foams as well as the pitch of the structures leads to changes and extension of the flat regions of the CFD curves.

[0232] Example 22: Ex22

[0233] Onto a metal tool treated for release with the structure shown in Fig. 15C was coated UV curable silicone from preparatory example 5. The silicone resin was coated into a tool with the structures shown in Fig. 15C and then the excess silicone was bladed from the surface of the plate with a polypropylene blade, such that the resin was only in the structures of the tool. The tool was placed under UV blacklight with dominant wavelength at ~350nm and an intensity of ~6mW / cm2. The sample was left to cure for 15 minutes to crosslink the silicone.

[0234] While the silicone was curing under UV, into a size 40 speed mixer cup was added 22.56 g of preparatory example 3 (Part A) and 6.09 g of preparatory example 4 (Part B). The silicone was mixed at 3200 rpm for 0.5 min. The mixture was coated between the metal tool filled with partially cured silicone from preparatory example 5 and a 2mil M64K7 silicone coated liner from Mitsubishi with a coating gap of 10.5 mil. The coating was cured in a 90°C forced air oven for 15 minutes. Following curing, the silicone foam was removed from the tool and the PET liner was permanently bonded to the nonstructured side of the silicone foam. The resulting silicone foam layer (minus the M64K7 thickness) had a thickness of2.336 mm and a bulk density of 0.41 g / cm3. A sample of the resulting structured foam was prepared for imaging with optical microscopy via cross sectioning with a razor blade through the thickness of the materials and mounting the sample edge on a supporting fixture. The optical micrograph can be seen in Fig. 18A where the white scale bar represents 400 microns. It can be clearly seen that the structures are a solid crosslinked resin and the base comprises a polymeric foam.

[0235] Lastly, Figure 18B shows compression force deflection (CFD) data for Example 22 in comparison to comparative example, CE 2. If can clearly be seen structuring the foam with solid structures can result in a large change in the CFD responses and extend the flat region of the CFD curves.

[0236] Test Methods

[0237] Density measurements were done on die punched 45.1 mm diameter specimens. Mass in grams was measured with a scale. Thickness was measured with a digital thickness gauge using a 28 mm diameter pressure foot and an applied mass of 10 g. Density in grams per cubic centimeter was calculated by dividing the specimen mass by the volume.

[0238] Thermal conductivity of the structured foams was measured with a TA Instruments Fox 50 Heat Flow Meter. 2 inch diameter circular discs were punched out of each foam sample. The top platen temperature was set to 70°C and the bottom platen was set to 50°C. A platen pressure of 25 psi was applied to the compress the foam between the platens. Once the top and bottom platens reach temperature setpoint, the platen displacement and thermal flux are measured repeatedly until reaching equilibrium. A thermal conductivity is reported at equilibrium based on the sample dimensions.

[0239] Compression force deflection (CFD) measurements were measured on the foams. 50.8 mm diameter circular discs were punched out of each foam sample. Samples were loaded between parallel platens in an Instron Model 5581 with a 5kN load cell. Compressive load was recorded for three consecutive compressions from 0-90% strain with a constant displacement of 1 mm / minute. Test followed TMAE No.: 1034 with a modified preload of 725 Pa. The 3rd cycle was used for evaluation and reported in Figures herein.

Claims

What is claimed is:

1. An article, comprising:• a first polymeric foam base layer comprising a crosslinked elastomeric material, wherein the polymeric foam base layer has a first major surface, a second major surface opposite the first major surface,• a first set of structures extending outwardly in a repeating pattern from the first major surface of the base layer in the thickness direction,• a predominantly inorganic layer adjacent, preferably immediately adjacent, to the second major surface of the base layer, wherein the first set of structures are made of the crosslinked elastomeric material.

2. An article according to claim 1, further comprising:• a second polymeric foam base layer comprising a crosslinked elastomeric material, wherein the second polymeric foam base layer has a first major surface and a second major surface opposite the first major surface, wherein the first major surface of the second polymeric foam base layer is adjacent, preferably immediately adjacent, the predominantly inorganic layer,• a second set of structures extending outwardly in a repeating pattern from the second major surface of the second base layer in a direction opposite from the direction of the first set of structures, wherein the first and second sets of structures are made of crosslinked elastomeric material.

3. An article according to any of the preceding claims, wherein the crosslinked elastomeric material is a foamed material chosen from silicone, polyurethane, and polyamides, preferably silicone.

4. An article according to any of the preceding embodiments, wherein the structures for the first set and / or second set (when present) are chosen independently of each other, and are prisms with a cross section having a shape chosen from triangular, truncated triangular, square, rectangular, and a shape defined by a cubic Bezier function (e.g., dome shape, and bullet-like shape) preferably a truncated triangular shape.

5. An article according to any of the preceding embodiments, wherein the structures for the first set and / or second set (when present) are chosen independently of each other, and are prisms with a cross section having a shape chosen from triangular, truncated triangular (or trapezoid), square, rectangular, and a shape defined by a cubic Bezier function (e.g., dome shape, and bullet-like shape) preferably a truncated triangular, wherein adjacent prisms are not touching each other.

6. An article according to any of the preceding embodiments, wherein the first set of structures and / or the second set of structures, independently from each other, comprise two or more different types ofstructures, and wherein the difference between the structures are chosen from differences in cross- sectional shape, and differences in spacing between the structures.

7. An article according to any of the preceding embodiments, wherein a set of structures (first or second set, each with the ratios below chosen independently from each other) has a height hi and the article has a total height 112, wherein the ratio of hi / h2 ranges from about 0.03 to about 0.65, or from about 0.05 to about 0.6, or from about 0. 1 to about 0.6 or from about 0.2 to about 0.05, or from about 0.25 to about 0.5.

8. An article according to any of the preceding embodiments, wherein a set of structures (first or second set, each with the ratios below chosen independently from each other) has a height hi and the article has a total height I12, wherein the ratio of hi / h2 ranges from about 0.05 to about 0.95, or from about 0.1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95.

9. An article according to any of the preceding embodiments, wherein a set of structures (first or second set, each with the ratios below chosen independently from each other) has a height hi and the article has a total height I12, wherein the ratio of hi / h2 ranges from about 0.05 to about 0.95, or from about 0.1 to about 0.95, or from about 0.5 to about 0.95 or from about 0.7 to about 0.95, wherein the width (base) of the structures is Pi, wherein the distance between two contiguous prisms is the pitch, P2, and wherein the ratio of P2 / Pi is from 1 to about 10, or from about 2 to about 8, or from about 2 to about 6, or from about 2 to about 4.

10. An article according to any of the preceding embodiments, wherein the structures for the first set and / or second set (when present) are chosen independently of each other, and are prisms with a cross section having a shape chosen from triangular, truncated triangular (or trapezoid), square, rectangular, and a shape defined by a cubic Bezier function (e.g., dome shape, and bullet-like shape) preferably a truncated triangular, wherein the width (base) of the structures is Pi, wherein the wherein the distance between two contiguous prisms is the pitch, P2, and wherein the ratio of P2 / Pi is from 1 to about 10, or from about 2 to about 8, or from about 2 to about 6, or from about 2 to about 4.

11. An article according to any of the preceding embodiments, wherein the crosslinked elastomeric material of the first base layer (and / or the second base layer when present) and the material of the first set of structures and / or the second set of structures (when present) is the same.

12. An article according to any of the preceding embodiments:• an polymeric foam base layer comprising a crosslinked elastomeric material, wherein the polymeric foam base layer has a first major surface, a second major surface opposite the first major surface,• a first set of structures extending outwardly in a repeating pattern from the first major surface of the base layer in the thickness direction,• a predominantly inorganic layer adjacent, preferably immediately adjacent, to the second major surface of the base layer, wherein the first set of structures are made of solid material (non-foamed).

13. An article according to any of the preceding embodiments, wherein the predominantly inorganic layer comprises one or more thermally resistant layers.

14. An article according to any of the preceding embodiments, wherein the article further comprises an encapsulating layer surrounding the other elements of the article.

15. A battery module comprising at least two battery cells and an article according to any of the preceding embodiments.

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